MASSENZA S.R.L.
TYPE FAE/1-3 WITH MOTOR
MASSENZA
PUMP TYPE
FAE/1-3 WITH MOTOR
USE AND MAINTENANCE
MANUAL
Publication attached to the pump
Type FAE/1-3
Year of construction 2008
Model with by-pass
Written on the 18/01/96
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[email protected] MASSENZA S.R.L. TYPE FAE/1-3 WITH MOTOR
This manual has been written in accordance with
the requirements stipulated in
the EN 292/2 regulations p. 5.
This manual has 14 pages
The preface should be read before going further
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PREFACE
The MASSENZA S.R.L. Company is pleased to welcome you amomgst its customers, and to thank
you for selecting one of its pumps. These are designed and made using the latest and most modern
techniques, and we trust that their use will give complete satisfaction.
WARNING!
This manual contains all the information needed for the installation and correct use of the pump,
and for its maintenance.
You are advised to read it attentively, before attempting to carry out any work on/with the pump.
Keep this manual in a readily accessible place known to everyone concerned, so that it will always
be available for consultation.
If any further information is needed, do not hesitate to contact us. We shall be pleased to give all
the necessary assistance.
If you should need spares, check with the appropriate section of the manual and then contact us
directly. This will enable us to give you the fastest possible service.
IMPORTANT !
Correct maintenance and strict attention to the requirements given in this manual, will ensure
that your pump works correctly, and that it will have the longest possible life.
The MASSENZA S.R.L. Company will not be responsible for any damage caused due to
incorrect pump use, or caused by the use of spares not made by the Company.
This publication must not be copied or reproduced, even partially, without the prior
authorisation of the MASSENZA S.R.L. Company.
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MASSENZA S.R.L. TYPE FAE/1-3 WITH MOTOR
INDEX
CHAPTER 1 : GENERAL INSTRUCTIONS PAGE 05
• GENERAL DESCRIPTION PAGE 05
• TECHNICAL SPECIFICATIONS PAGE 05
• SAFETY DEVICES PAGE 06
• ORDINARY MAINTENANCE OPERATIONS PAGE 06
CHAPTER 2 : INSTALLATION PAGE 06
• CHECKS ON RECEIPT PAGE 06
• LIFTING PAGE 06
• PLACING PAGE 06
• SUGGESTIONS FOR CORRECT INSTALLATION PAGE 07
• ELECTRICAL CONNECTIONS PAGE 08
• STARTING PAGE 08
CHAPTER 3: PROBLEM ANALYSIS PAGE 09
• MECHANICAL BREAKDOWN. PAGE 09
• ELECTRICAL FAILURES PAGE 09
• OPERATING PROBLEMS PAGE 09
CHAPTER 4: MISUSE AND DAMAGING ACTIONS PAGE 10
• MISUSE PAGE 10
• DAMAGING ACTIONS PAGE 10
CHAPTER 5: ADJUSTMENT AND FINE TUNING PAGE 10
• CALIBRATION OF THE BY-PASS VALVE PAGE 10
• ADJUSTING THE BY-PASS PRESSURE PAGE 11
• CHANGING THE SEALS PAGE 11
• REMOVING THE GEARS PAGE 11
CHAPTER 6: SPARE PARTS PAGE 12
• INTRODUCTION PAGE 12
• HOW TO ORDER SPARE PARTS PAGE 12
LIST OF DIAGRAMS AND TABLES
• DIAGRAM WITH OVERALL DIMENSIONS PAGE 05
• TROUBLESHOOTING TABLE PAGE 09
• EXPLOSION DIAGRAM PAGE 13
• PARTS’ TABLE PAGE 14
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CHAPTER 1: GENERAL INSTRUCTIONS
1.1 GENERAL DESCRIPTION
Esternal Pumps Type FAE are volumetric gear pumps which are very compact, and which have
heating jackets. These enable them to be used for pumping fluids which, due to their high viscosity,
require to be handled at high temperature.
The Type FAE Pumps consist of :
• A cast iron G 25 body, helicoidal gears in treated steel, self lubricating bearings and packed seals
within pre-formed rings.
• By-pass for maximum pressure.
Diagram with overall dimensions
1.2 Technical Specifications
TYPE DELIVERY RPM’S MOTOR DIMENSIONS DIMENSIONS DIMENSIONS DIMENSIONS
L./MIN. KW. A B C D
FA 1 15 1450 0.7 98 “ 215 1/2”
FA 2 30 1450 1.1 108 “ 226 1/2”
FA 3 50 1450 1.5 116 20 226 3/4”
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1.3 SAFETY DEVICES
The pumps have been developed continuously over the years, and this has given them a high level
of safety in operation.
The main operator safety items are the guards protecting the coupling between the motor and the
pump.
If these guards need to be dismantled to check the coupling alignment, or for any other reason, they
must be re-positioned correctly before using the pump.
The pump must not be used without these guards in position.
.
1.4 ORDINARY MAINTENANCE OPERATIONS
FA Type pumps do not require any special maintenance.
Nevertheless you are advised to :
• Change the seals when they allow product to leak during use.
CHAPTER 2 : INSTALLATION
2.1 CHECKS ON RECEIPT
When the packaging is opened check that all the parts are present, and that none of them is
damaged.
Any damaged or missing parts must be reported to the MASSENZA S.R.L. Company immediately.
N.B. If the pump is supplied complete with its baseplate and motor, check the alignment of the shaft
coupling and the distance between the coupling face plates. This should be 3 to 4 mm.
2.2 LIFTING
Heavy pumps have a provision for attaching a lifting eye so that the pump can be lifted in a
balanced and stable state.
Cables and ropes used for lifting must be adequate for the weight to be lifted, and must not have
broken strands or show other signs of wear.
2.3 PLACING
There are holes in the baseplate for anchoring the pump, so that it does not move about whilst it is
in service.
Use all the holes provided.
The bolt diameters must match the sizes of the holes in the baseplate.
It is essential, when the pipes are connected to the pump connections, that the joints are made
without forcing the pipes into position, and that the pump does not have to support the pipes.
We advise you to install pressure gauges on the pump suction and delivery pipes.
The pressure data is essential in order to evaluate the working conditions of the pump.
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2.4 SUGGESTIONS FOR CORRECT INSTALLATION
The suction pipe :
In all pumping installations the greatest attention needs to be given to the suction pipe installation.
It is sound practice to position the pump at the lowest possible level with respect to the minimum
level of the liquid to be pumped.
The suction pipe should always be as short as possible; its diameter must be as large as possible (as
for all plant accessories), and it must never be less than the diameter of the pump inlet flange bore.
If possible it should be greater than the flange bore, especially if the intention is to pump viscous
fluids.
Ensure that the open end of the suction pipe is always free, and that it does not rest on the bottom of
the tank. It is good practice for the opening to be cut on a slant.
The suction pipe must always be fitted with a strainer, to ensure that foreign bodies are not sucked
into the pump.
The delivery pipe:
The delivery pipe does not have any special requirements in regard to its diameter, height, or
accessories. However, it should be remembered that a smaller diameter, a pipe run with many bends
and an excessive length, all absorb energy and give a higher energy consumption.
When the pump has a by-pass on the delivery pipe, it is not necessary to install a by-pass valve.
This would be necessary otherwise, in order to prevent damage due to mistakes in operation - such
as closing a valve on the delivery side whilst the pump is running.
Plat of diathermic oil, to heat:
All our pumps can we supplied with heating-camber.
After installing the pump in the plant, you can make the diathermic oil pipe fixed.
The diameter of the pipes must be the same or more of our dimension on the pump.
The suction pipe is in the position of B letter.
The delivery pipe is in the position of A letter.
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2.5 ELECTRICAL CONNECTIONS
The electrical plant must be constructed in conformity with the European Standard for machine
safety EN 60204-1.
There must be adequate provisions against electrocution, short circuits and overloads.
The electrical components used must all conform to the applicable regulations.
All motors must be provided with magnetic thermal overload devices to prevent overheating due to
overload.
The electrical plant feeding the motor must be fitted with protections against indirect contacts.
These must include the connection of the protective circuit to earth, and an external safety device
which ensures that the power is cut off automatically in the event of damage to, or breakdown of the
insulation.
NB. THE ELECTRICAL PLANT MUST BE ASSEMBLED BY SPECIALISED
TECHNICAL PERSONNEL
2.6 STARTING
Before starting the pump, check that it turns freely and without forcing.
Check that the motor turns in the correct direction, as shown by the arrow marked above the pump.
To identify the delivery side, look at the pump from the shaft end. If the pump runs clockwise, the
delivery is on the right hand side and the suction on the lefthand side.
N.B. BEFORE SWITCHING ON THE PUMP MAKE SURE THAT ALL THE PLANT
VALVES ARE OPEN
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CHAPTER 3 : PROBLEM ANALYSIS
3.1 MECHANICAL BREAKDOWN
With the help of the tables which list all the pump change parts, it will be easy to identify and
correct any breakdowns which may occur.
3.2 ELECTRICAL FAILURES
We recommend that any electrical failures should be examined, identified and repaired by
appropriately specialised personnel.
3.3 OPERATING PROBLEMS AND BREAKDOWNS
Operating problems and breakdowns are usually caused by devices being incorrectly set or
incorrectly installed.
The following table will be of assistance in correcting the various problems that may arise during
the pump operation.
PROBLEM CAUSE REMEDY
The pump delivery is - The motor speed is not that shown - Check, and if necessary change
less than the by the maker. the motor.
required/nominal - The liquid to be pumped cannot - Check the suction and delivery
delivery. reach/enter the inlet pipe in sides to ensure that there are no
sufficient quantity. blockages (stones, rags, etc.),
that the valves are all open and
that the filter is not blocked, that
the suction inlet is not touching
the bottom of the tank and that
old tubes have not become
reduced in effective diameter due
to surface deposits.
- The by-pass valve is set at too low - Re-calibrate the valve - see Chapter
a pressure. on Adjusting & Fine Tuning.
Excessive noise. - The product temperature is too low - Raise the product temperature.
- The pump is not heated sufficiently - Check this, and if necessary heat
the pump jacket using diathermic
oil.
The pump shaft is - The coupling is not aligned - Re-align the coupling and make
locked and does not correctly. sure that the two halves are at
turn. least 3 to 4 mm. apart.
- The gears cannot turn due to - Dismantle the gears as shown in
the presence of a foreign body. the chapter Adjustment & Fine
Tuning. Remove any foreign ob-
jects and re-assemble the gears.
Liquid loss from the - The seal is too slack. - Adjust the seal material as shown
seal. in the chapter Adjustment &
Fine Tuning.
- Theseal is worn out. - Change the seal material as
shown in the chapter :
Adjustment & Fine Tuning.
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CHAPTER 4: MISUSE, AND DAMAGING ACTIONS
4.1 MISUSE
Our pumps are designed for use with liquids at a high temperature, with a maximum temperature of
300oC.
The pumps must only be used for the products listed by the maker.
The pump rotation speed must not exceed that given by the maker.
N.B. THE MAKER WILL NOT TAKE ANY RESPONSIBILITY FOR DAMAGE CAUSED
BY USING THE PUMP BEYOND THESE RESTRICTIVE LIMITS.
4.2 DAMAGING ACTIONS
Customers must not:
• Allow the pump to run empty, as this may ruin the gears beyond repair.
• Remove the safety guards, or run the pump with the safety guards removed.
• Carry out maintenance operations with the pump powered.
• Carry out maintenance operations when the pump is running.
CHAPTER 5 : ADJUSTMENT AND FINE TUNING
CAUTION !
DANGEROUS
TEMPERATURES
UP TO 300°C
5.1 CALIBRATING THE BY-PASS VALVE
All FA pumps can be fitted with by-pass valves. When the pump has been installed on the plant, it
is necessary to carry out the calibration of the by-pass valve.
To carry out this operation it is necessary to install a pressure gauge on the delivery line and to refer
to the diagram on page 13.
1. Check that the motor is running at the correct speed, and that the shaft coupling safety guard is in
place.
2. Partially close a gate valve in the delivery line, until the gauge shows a pressure greater than the
one required.
3. Remove the by-pass cover (item 9 page 13).
4. Unscrew the nut, item 13
5. Using a screw driver, turn the square clockwise until the pressure in the delivery line starts to
fall.
6. Turn the same square anti-clockwise until the required pressure is shown steadily on the gauge.
This must always be less than 7 bar.
7. Turn the nut, item 13
8. Replace the cover (item 9).
Note: This calibration must NEVER be carried out using water, as the pump may be
damaged beyond repair.
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5.2 ADJUSTING THE BY-PASS PRESSURE
Proceed as described above in the previous paragraph, as for the calibration of the by-pass valve,
remembering that the pressure can be varied according to requirements. Remember also, that the
delivery pressure of this type of pump must never exceed 7 bar.
If the delivery pressure needs to be changed proceed as follows and refer to the explosion diagram
on page 13 :
1. Unscrew the by-pass cover (item 9);
2. Unscrew the nut, item 13
3. Using a screw driver, turn the square anti-clockwise to raise the pressure;
4. Turn the key clockwise to lower the pressure;
5. When the required pressure is shown steadily on the gauge, turn the nut, item 13
6. Replace the cover (item 9).
5.3 CHANGING THE SEALS
To change the packed seals proceed as described below, and refer to the diagram on page 13.
1. Switch off the power supply to the plant in which the pump is installed.
2. Remove the flexible coupling guard.
3. Remove the electric motor.
4. Remove the coupling half from the pump shaft, taking care to loosen the grub screw.
5. Remove the shaft key from the pump shaft, (item 15).
6. Unscrew the two pressure nuts, (item 20).
7. Remove the packing pressure piston, (item 3).
8. Remove any packing residues (item 8).
9. Insert the new packing and replace the packing piston (item 3). Make sure that the two nuts are
not tightened excessively (item 20).
10. Replace all the items removed, after cleaning all the mechanical parts well.
5.4 REMOVING THE GEARS
Whilst the pump is in use foreign bodies may pass the line filter and block the gears preventing
them from turning, and the pump does not work.
Should this happen we recommend that the pump should be maintained by specialised personnel, as
an incorrect re-assembly after cleaning could seriously reduce the pump life.
To remove the gears proceed as described below, making reference to the diagram on page 13 :
1. Isolate the electric power from the plant on which the pump is installed.
2. Remove the flexible coupling guard.
3. Remove the pump motor.
4. Remove the half coupling on the pump shaft.
5. Remove the key from the pump shaft.
6. Unscrew the six Allen BOLTS (item 17).
7. Remove the front support (item 2).
8. Clean every part removed minutely, and extract the gears, parts 4 and 5 (exploded view).
9. Check the condition of the gears and the pump chamber, clean every part as above and
lubricate the bearings well.
10. Replace the gears, parts 5 and 4 (exploded view).
11. Replace the support after fitting the support gasket (item 7), making sure that the location pin is
in its correct place.
12. Replace and tighten the six Allen bolts (item 17).
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13. Replace all the remaining elements removed previously.
N.B. To ensure that there is no risk of the pump seizing, all the moving and static parts must
be scrupulously cleaned.
CAUTION !
ALL THE ABOVE OPERATIONS
MUST BE CARRIED OUT WITH
THE MOTORS SWITCHED OFF
AND WITHOUT POWER
The MASSENZA S.R.L. Customer Service Organisation is always available to give technical
assistance.
CHAPTER 6 : SPARE PARTS
6.1 INTRODUCTION
The components and the spare parts of the standard versions of the pump can be identified by
referring to the table on page 13.
The MASSENZA S.R.L. Company will not be responsible for any damage arising from the
use of spares which are not made by the Company, or which are due to the operators
tampering with the pump.
6.2 HOW TO ORDER SPARE PARTS
When ordering spare parts the customer must supply the following information:
• The pump type, the serial number and the year of manufacture. These are shown on the pump
plate.
• The code number and the part descriptions given in the table of spares, for every part ordered.
• For each part, the number to be supplied.
WE RECOMMEND THAT
ANY WORK ON THE PUMP
SHOULD BE CARRIED OUT
BY EXPERT PERSONNEL
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MASSENZA S.R.L. TYPE FAE/1-3 WITH MOTOR
EXPLODED VIEW OF PUMP TYPE FAE/1-3
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MASSENZA S.R.L. TYPE FAE/1-3 WITH MOTOR
TABLE OF PARTS: PUMP TYPE FAE/1-3
POSITION QUANTITY CODE DESCRIPTION
1 1 0012/1 PUMP BODY
2 1 0012/2 SUPPORT
3 1 0012/3 SEAL COVER
4 1 0012/4 PRIMARY GEAR
5 1 0012/5 SECONDARY GEAR
6 4 0012/6 BEARINGS
7 1 0012/7 GASKET
8 3 0012/8 SEAL
9 1 0012/9 BY-PASS COVER
10 1 0012/10 SPRIG
11 1 0012/11 BY-PASS SCREW
12 1 0012/12 BY-PASS VALVE
13 1 0012/13 BOLT
14 1 0012/14 BY-PASS CAP
15 1 0012/15 KEYWAY KEY
16 2 0012/16 ELASTIC PINS
17 6 0012/17 SCREW TEIC
18 2 0012/18 STUDS
19 2 0012/19 SCHNORR
20 2 0012/20 NUTS
21 1 0012/21 FLANGE FOR PACKING
22 2 0012/22 PACKING
23 2 0012/23 GASKETS
24 1 0012/24 FLANGE FOR PACKING
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